Note: Descriptions are shown in the official language in which they were submitted.
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'-- PLASTIC INLET APPLIANCE WATER VALVE
by
Steven William Smock and Neil Edward Grah
BACKGROUND
This invention relates to water valves and more specifically to solenoid operated
inlet water valves used on household appliances.
Inlet water valves have been used on household appliances such as ice makers,
10 dishwashers, and clothes washers for many years to control the flow of water into the
appliance. Inlet water valves are typically attached to the appliance with an inlet
connector attached with a union connector to a water source pipe, and the inlet water
valve outlet is connected to the appliance. A solenoid operated by the appliance
~tu~tes a valve to permit or stop water flow into the appliance. The solenoid can either
15 directly actuate the valve or can operate a pilot valve to actuate the valve.
The manufacturing of inlet water valves has become increasingly competitive and
the most desirable inlet water valve designs have the fewest parts and the fewest
manufacturing steps. The use of fewer parts and fewer manufacturing steps generally
results in decreased cost and increased quality. Also, new regulations such as California
20 Proposition 65 which may require removal of all lead, even the small amount almost all
brass contains for machining purposes, from all home appliances that contact potable
water in the near future. Another concern of appliance manufacturers is to have an inlet
valve that is easy to connect to a water source pipe preferably without the use of tools.
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Some prior art water valves 20P, such as shown in FIGS. 1, 2, and 3, have inlet
connectors 22P, that are brass. A brass plate 24P is attached to the water valve inlet
26P and a brass elbow 28P is screwed into the brass plate 24P to provide an inlet
connector 22P. Brass inlet connectors are expensive to manufacture. Additionally, lead
contained in the brass inlet connector can leach into water used by the appliance.
Some prior art inlet connectors have a connector insert that is fixed in the inlet
connector and the water source pipe is attached to the connector insert. Connector
inserts are often made of brass because of its anti-corrosion properties and strength.
Also some prior art valves use a brass insert in a plastic inlet connector and a brass
compression fitting to attach the water source pipe. An example of a plastic inlet
connector with a brass insert and compression fitting is disclosed in U.S. Pat. No.
4,697,608 issued to Kolze et al.
Some prior art valves have used quick connect/disconnect t,vpe connectors on theinlet connector. Quick connect/disconnect type connectors typically include several
parts such as O-ring seals, grip rings, spacers, and a threaded nut. The O-ring is a
quick connect/disconnect co"nector are vulnerable to damagè when the water source
line is inserted into the connector. If the water source line has a bur or sharp edge the
O-ring can be damaged causing a leak. Additionally, over time O-rings can lose their
elasticity and- can cause leaks. An example of the use of a quick connectldisconnect
connector on an ice maker is disclosed in U.S. Pat. No. 4,889,316 issued to Donahue,
Jr.
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Some prior art water valves, such as shown in FIG. 4, inlet connectors do not have
a connector insert but are configured instead configured to accept a garden hose style
connector. Although this reduces components compared to inlet connectors 32P with
connector inserts, garden hose connectors have a tendency to leak because a portion
5 of the connector is typically soldered. During the life of the appliance, vibration can
cause this solder joint to crack and leak water. Additionally, solder typically contains
lead which will be discouraged or prohibited in consumer appliances dispensing drinking
water under laws such as California Proposition 65, The Safe Drinking Water and Toxic
Enforcement Act of 1986.
For the foregoing reasons, there is a need for an inlet water valve connector that
does not contain brass, contains fewer parts, eliminates the need for union connector,
is more reliable, is less expensive to produce, reduces the number of rejected parts for
failure to meet quality standards, less likely to leak compared with a garden hose style
connector, and can be configured with an exit angle that reduces the need for the water
15 source pipe to make tight bends.
SUMMARY
We have invented an apparatus and method that satisfies the need for an
appliance water valve with an all plastic integral inlet connector angled from about 30-90
degrees to the inlet. The plastic inlet appliance water valve comprises the following. A
20 water source pipe which supplies water to the appliance. A valve body having an inlet
that controls the input of water from the water source pipe to the appliance. A frame for
attaching the valve body to the appliance and the frame is shaped to protect the plastic
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inlet connector from damage. A ferrule nut used to attach the water source pipe to the
water valve. A plastic inlet connector having a ferrule seat attached to the inlet for
receiving the water source pipe and a shoulder that is integral to the ~lastic inlet
connector for properly positioning the water source pipe.
The method for attaching a water source pipe to an appliance water valves,
comprises the following steps. A water source pipe is provided to the appliance water
plasbc inlet appliance water valve. A plastic inlet connector is provided that is attached
to the water valve body having a water source orifice for receiving the water source pipe,
a threaded connector surrounding the water source orifice and a ferrule seat around the
upstream periphery of the water source orifice. A ferrule nut is also provided having a
ferrule seal, a gripper, and threads that cooperate with the threaded receptacle for
attaching the ferrule nut to the plastic inlet connector and a nut bore sized to accept the
water source pipe.
The ferrule nut threads are engaged on the threaded connector surrounding the
water source orifice. The water source pipe is inserted through the ferrule nut bore and
into the water source orifice until the water source pipe rests on a shoulder on the
downstream end of the water source orifice. The ferrule nut is then tightened causing
the ferrule seal to engage the ferrule seat of the plastic inlet connector. A seal i~ formed
between the inlet orifice and the water source pipe by the ferrule seal engaging the
ferrule seat and pressing against the water source pipe. Finally, the water source pipe
is gripped by the ferrule nut gripper that is angled to wedge the water source pipe in the
inlet orifice.
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The invention provides the following. Meet anticipated reguiatory
requirements to eliminate parts containing lead, e.g. brass, in household appliances
using potable water by providing an all plastic inlet that eliminates the need for brass
fittings which can contain lead. Decrease the manufacturing costs and increase qualit,v
by reducing the number of manufactured parts required to produce an appliance inlet
water valve. Eliminate the need to use a union connector to attach the water source pipe
to the inlet connector. Create an easier to install appliance inlet water valve that does
not require tools to attach the water source pipe to the inlet connector. Eliminate leaks
caused by garden hose connector broken solder joints on appliance inlet water valves
by eliminating garden hose connectors. Decrease water source pipe kinks and
obstructions by having the inlet connector make a 30-90 degree bend rather than the
water source pipe. Decrease water inlet flow noise caused by cavitation. Eliminate
leakage that can occur around a brass insert or brass insert gasket in the inlet connector
by eliminating the need for a brass insert.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the present invention will
become better understood with regard to the following description, appended claims,
and accompanying drawings where:
FIG. 1 shows a prior art inlet water valve with a brass inlet connector;
FIG. 2 shows a prior art brass inlet elbow;
FIG. 3 shows another view of the prior art brass inlet elbow;
FIG. 4 shows a prior art inlet water valve with a garden hose inlet connector;
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FIG. 5 shows an inlet water valve with a plastic inlet connector;
FIG. 6 shows another view of the inlet water valve with the plastic inlet
connector;
FIG. 7 shows a view of the plastic inlet connector surface that attaches to the
water valve inlet;
FIG. 8 shows a view of the plastic inlet connector water source orifice;
FIG. 9 shows a sectioned view of the plastic inlet connector;
FIG. 10 shows a sectioned view of the plastic inlet connector attachment bore;
FIG. 11 shows an exterior view of the plastic inlet connector;
FIG. 12 shows a ferrule nut with water source pipe engaging the plastic inlet
connector;
FIG. 13 shows a ferrule nut;
FIG. 14 shows another view of a ferrule nut;
FIG. 15 shows an inlet water valve with a plastic inlet connector attached to a
valve body inlet with a weldment;
FIG. 16 shows an isometric view of the plastic inlet connector; and,
FIG. 17 shows another isometric view of the plastic inlet connector.
FIG. 18 shows the main components of the invention.
DETAI~ED DESCRlFrION
Refe" il ,~ to FIGS. 5 and 6, an appliance inlet water valve 40 of the type typically
found in a refrigerator freezer ice maker is shown. The water valve 40 is typically
attached to the back or bottom of the refrigerator with a metal frame 42 and a water
source pipe 46 (FIG. 12) is run from a residential water line to the water valve inlet
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onnector 44
An appliance water valve 40, having features of the invention, comprises: a water
source pipe 46 for supplying water to the appliance; a valve body 48 having an inlet 74
controlling the input of water from the water source pipe46 to the appliance; a ferrule
nut 52 (FIG. 12) for attaching the water source pipe 46 to the water valve 40; and, a
plastic inlet connector 44 having an integral ferrule seat 54 attached to the inlet
connector 44 for receiving the water source pipe 46 and ferrule nut 52. The plastic inlet
connector 44 may have a gusset for strengthening the plastic inlet connector 44 and
providing alignment for a mounting bracket.
The water source pipe 46 found in a residential house can take a variety of forms
such as a plastic or copper pipe with a diameter of typically 0.25 inches (0.635 cm).
Water source pipes 46 are often located in areas that are not out in the open such as
under sinks, in kitchen corners, and behind refrigerators which may be dark and
cramped. In such spaces maneuvering tools can be difflcult.
The valve body 48 having an inlet connector 44 is molded preferably from a plastic
such as a Food and Drug Agency (FDA) grade polypropylene. The valve body 48 in
addition to the inlet connector 44 has a valving calving cavity, a guide tube, an armature,
field windings, a diaphragm, a diaphragm insert (not shown), and an outlet 56. A metal
frame 42 is attached to the valve body 48 for mounting the water valve 40 to theappliance, supplying an electrical ground connection, and for protecting the inle~
connector 44 from damage. The plastic inlet connector 44 often extends beyond the
back of an appliance such as on a refrigerator to facilitate connection of the water source
line 46 to the plastic inlet connector 44 by the customer or installer. Since the- plastic
inlet connector 44 may not be protected by the appliance cabinet (not shown), the
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plastic inlet connector 44 can be damaged when moving an appliance or during
appliance installation. The water valve metal frame 48 is typically constructed of a 14
gauge 1008/1010 steel and shrouds the plastic inlet connector 44 on three sides to
protect the plastic inlet connector 44 from damage.
Referring to FIGS. 12, 13 and 14, the ferrule nut 52 comprises a plastic nut 60 with
indentations 62 for hand tightening; a gripper 64 for engaging the water source pipe 46
to prevent the water source pipe 46 from slipping out of the plastic inlet connector 44;
and, a ferrule sleeve 66 having a body 68 that slideably engages the ferrule seat 54 and
a projection 70 that is pressed by the body 68 and ferrule seat 54 against the water
source pipe 46 to form a water-tight seal. Ferrule nuts 52 have been used for many
years on a variety of applications. The ferrule gripper nut 52 is made of a plastic and
designed to accept a 0.25 inch (0.635 cm) diameter pipe. If a larger or smaller water
source pipe 46 will be used, a larger or smaller ferrule nut 52 will also be required. The
plastic nut has indentations 62 for hand tightening without tools. The indentations 62 in
the ferrule nut 52 can take a wide variet,v of forms including a standard hex head nut.
Since generally the torque required to install a plastic ferrule nut 52 can be provided by
a bare hand, the indentation 62 need only be fashioned to provide some friction between
the ferrule nut 52 and a bare hand, so the ferrule nut 52 can be installed even when wet
and slick. The use of a ferrule nut 52 perrnits the water source pipe 46 to be installed
typically without tools which is an advantage because water source lines 46 are often
connected to inlet water valve 40 in a cramped, poorly lit space where tools can be
difficult to use.
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Referring to FIG. 12, the ferrule nut sleeve 66 has a body 68 that slideably
engages the ferrule seat 54 and a sealing projection 70 that is pressed by the body 68
and ferrule seat 54 against the water source pipe 46 to form a water-tight seal. The
ferrule seat 54 is ramped, so as the ferrule nut 52 is tightened with the ferrule sleeve 66
5 slideably engages the ferrule seat 54 the ferrule sleeve 66 slides farther up the ramped
ferrule seat 54. As the ferrule sleeve 66 moves farther up the ramp 54, the ferrule seal
body 68 presses the sealing projection 70 tighter against the water source pipe 46 to
create a water-tight seal.
The ferrule nut gripper 64 engages the water source pipe 46 to prevent the water
source pipe 46 from slipping out of the plastic inlet connector 44. The gripper 64 can
be made of a variety of materials such as plastic for use on plastic tubing or stainless
steel for use on a hard, smooth water source pipe 46 such as one made of copper. The
gripper 64 cooperates with the ferrule seal body 68 to engage the water source pipe 46
with a sharp edge 72. The gripper 64 is angled so if the water source pipe 46 is pulled
away from the plastic inlet connector 44 then the gripper 64 will engage the water source
pipe 46 with greater pressure to create more resistance for preventing the water source
pipe 46 from being pulled away from the plastic inlet connector 44. Ferrule nuts 52 such
as that described above are avaiiable from JACO Manufacturing Company, 468 Geiger
Street, Berea, Ohio 440t7.
Referring to FlGS. 5~11, the plastic inlet connector 44 is attached to the valve body
inlet 74 for receiving the water inlet pipe 46 (FIG. 12) and comprises a ferrule seat 54 that
is integral to the plastic inlet connector 44, an internal shoulder 76 that is also integral
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to the plastic inlet connector 44, an alignment collar 78, and a gusset 80. The plastic
inlet connector 44 is a one-piece molded part made preferably of an FDA grade
polypropylene and includes a gasket 82 typically made of rubber to create a.water-tight
seal when the inlet connector 44 is attached to the inlet 74. The inlet connector orifice
50 communicates with the inlet 74 and can be manufactured in a variety of angles to the
inlet 74 to permit the water source pipe 46 to connect more directly with less bends to
the plastic inlet connector 44. The ferrule seat 54 is designed to provide the proper
ramped surface for the ferrule sleeve 66 to engage when the ferrule nut 52 is tightened.
The gusset 80 is used for strengthening the plastic inlet connector and providesalignment for a mounting bracket.
The plastic inlet connector 44 can be attached to the inlet 74 in a variety of
methods. The plastic inlet connector 44 can be attached to the inlet 74 with self-tapping
screws 84 with a gasket 82 placed between the inlet connector 44 and the inlet 74 to
create a seal. Self-tapping screw relief cavities 86 are provided in the plastic inlet
connector 44, so when the plastic inlet connector 44 is attached to the inlet 74 self-
tapping displacement (not shown) from the inlet 74 can expand into the relief cavity 86.
The purpose for a relief cavity 86 is to ensure that the plastic inlet connector 44 seats
firmly against the inlet 74 to prevent leakage.
Referring to FIG. 15, the plastic inlet connector 44 can also be attached to the inlet
74 with a weldment 88 that uses no screws or gasket. The weldment 88 is formed by
rotating or vibrating either or both the inlet connector 44 and the valve body 48 to melt
the mating sur~aces on the intet connector 44 and inlet 74 to form a seal.
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Operation of the invention follows. Referring to FIG.12, the ferrule nut threads 90
are engaged with the threaded connector 92 surrounding the inlet connector cavity 5û.
It is an advantage of the invention that the water source pipe 46 can be connected
directly to the plastic inlet connector 44 without the use of a union connector (not
5 shown). The ferrule nut 52 is installed by attaching the ferrule nut 52 to the threaded
connector 92 without having the ferrule seat 54 apply significant pressure to the ferrule
sleeve 66. The water source pipe 46 is inserted through the ferrule nut bore 94 and into
the inlet connector cavity 50 until the water source pipe 46 rests on the shoulder 76 on
the downstream end of the inlet connector cavity 50. Since the plastic inlet connector
44 can be configured at a 30-90 degree angle relative to the inlet 74, the water source
pipe 46 can be attached to the plastic inlet connector 44 without making a sharp bend.
Sharp bends in the water source pipe 46 can create cavitation and thus noise. The
ferrule nut 52 is tightened causing the ferrule sleeve 66 to engage the ferrule seat 54 of
the plastic inlet connector 44. A seal is formed between the inlet connector cavity 50
and the water source pipe 46 by the ferrule sleeve 66 engaging the ferrule seat 54
causing the projection 70 to press against the water source pipe 46. Finally the water
source pipe 46 is gripped with the ferrule nut gripper 64 that is angled to wedge the
water source pipe 46 in the inle~cavity 50. The operational steps described above could
be done in a cJirr~ren~ order. For instance the water source pipe 46 could be inserted
20 through the ferrule nut bore 94 prior to engaging the ferrule nut threads 90 on the inlet
connector 44. Also the ferrule nut 52 operates so that as the ferrule nut 52 is being
tightened the sealing and gripping functions can occur simultaneously.
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The previously described versions of the present invention have many advantages,
including: Meeting anticipated requirements to eliminate parts containing lead that
contact potable water by providing an all plastic inlet 24 that eliminates the need for
brass fittings which can contain lead. Decreasing the manufacturing costs and increase
5 quality by reducing the number of manufactured parts required to produce an appliance
inlet water valve 40. Creating an easier to install appliance inlet water valve 40 that does
not require tools to attach the water source pipe 46 to the inlet connector 44. Eliminating
leaks caused by garden hose connector broken solder jolnts on appliance inlet water
valves 30P by eliminating garden hose connectors. Decreasing water source pipe 46
kinks and obstructions by having the inlet connector 44 make a 30-90 degree bend
rather than the water source pipe 46. Decreasing water inlet noise caused by cavitation.
Eliminating leakage that can occur around a brass insert or brass insert gasket in the
inlet connector 44 by eliminating the need for a brass insert.
Although the present invention has been described in considerable detail with
15 reference to certain preferred versions thereof, other versions are possible. For example
the plastic inlet connector 44 could be configured to accept a water source pipe 26 from
any direction. A ferrule nut 52 could be attached to the plastic inlet connector 24 with
captive threads, so when connecting the water source pipe 46 up to the plastic inlet
connector 44 the ferrule nut 52 could not be dropped or fall off the inlet connector 44.
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